Welding remains a fundamental process in precision manufacturing, critical to ensuring the strength, durability, and reliability of components across a range of industrial applications, from machinery and equipment to structural frameworks. With various welding techniques available, understanding their differences is key, especially when working with high-strength, wear-resistant, or heat-resistant materials used in demanding environments.
In this guide, we explore the most common types of welding used across modern industry, including MIG, TIG, Stick, and Submerged Arc Welding, along with more specialised methods such as laser and friction stir welding. Whether you’re assembling large-scale machinery, producing load-bearing structures, or working with custom-engineered components, this article will help you choose the right welding process for precision, performance, and compliance.
Overview of Common Welding Types
Welding is a core process in precision manufacturing, essential for ensuring the strength, integrity, and compliance of industrial components and assemblies. From high-load structures to thin-gauge materials, choosing the right welding method is critical, especially when working with advanced alloys or tight tolerances.
Below is a guide to the most common welding processes used across modern industry, focusing on their applications, advantages, and suitability for complex or high-performance projects.
1. MIG and MAG Welding
MIG (Metal Inert Gas) and MAG (Metal Active Gas) welding are forms of Gas Metal Arc Welding (GMAW). Both use a continuously fed wire and shielding gas, but differ in gas composition: MIG uses inert gases like argon, while MAG uses active gases such as CO₂ or mixed gases, making it ideal for steelwork.
These methods are widely adopted in both manual and automated systems due to their speed, reliability, and deep penetration, especially for medium to thick sections. Their high deposition rate and compatibility with automation make them well-suited for industrial-scale production environments.
2. TIG Welding
TIG (Tungsten Inert Gas) welding, or GTAW, is known for delivering exceptionally precise and clean welds. It uses a non-consumable tungsten electrode and inert shielding gas, typically argon, to protect the weld area.
TIG is ideal for thin materials, stainless steels, and high-alloy metals where visual finish, low heat input, and metallurgical control are essential. While slower than other methods, it’s preferred in applications where precision and purity are more important than speed.
This process is often used at Vulcanus for high-tolerance assemblies and components requiring resistance to cracking or thermal stress.
3. Shielded Metal Arc Welding (Stick)
Stick welding, or Shielded Metal Arc Welding (SMAW), is a widely used manual welding process. It relies on a flux-coated consumable electrode, which generates its own shielding gas and slag during welding, making it well-suited for outdoor use or field repairs.
SMAW is particularly useful when welding thicker materials in remote or variable environments. Its simplicity and low equipment requirements make it a flexible choice, especially for structural repair or heavy-duty work under non-ideal conditions.
4. Submerged Arc Welding (SAW)
Submerged Arc Welding is a high-efficiency, fully automated process where a granular flux covers the arc and molten weld. This setup allows for excellent shielding, minimal spatter, and deep penetration.
SAW is ideal for long, continuous welds on large sections such as beams, tanks, or base frames. Its consistent quality and high deposition rate make it a go-to choice in high-volume production of thick steel assemblies, particularly when standards like EN 1090 must be met.
5. Flux-Cored Arc Welding (FCAW)
Flux-Cored Arc Welding offers a hybrid between MIG’s speed and Stick’s versatility. It uses a tubular wire filled with flux, which can be self-shielding or used with external gas depending on the application.
FCAW is often chosen for thick, abrasion-resistant steels or outdoor work, due to its portability and tolerance for variable conditions. It also allows for strong welds with good distortion control, key in applications requiring both strength and dimensional stability.
Additional Types of Welding Techniques Used in Industry
While MIG, TIG, and Stick welding are widely used in industrial, there are other specialised welding techniques that play a critical role in automated manufacturing and high-precision applications. These processes are particularly valuable when working with dissimilar materials, heat-sensitive alloys, or complex geometries that require advanced control over the weld environment.
1. Laser Beam Welding (LBW)
Laser welding uses a highly concentrated beam of light to melt and fuse materials with remarkable precision and minimal heat input. This technique is particularly well-suited to thin-gauge metals and heat-sensitive materials, reducing the risk of distortion or cracking.
It is frequently used in the automotive, aerospace, and electronic industries, where intricate welds must be completed at high speeds with minimal thermal impact. With the advancement of robotic welding systems, laser welding has become increasingly integrated into automated fabrication lines, ensuring consistent quality across large production volumes.
2. Friction Stir Welding (FSW)
Friction Stir Welding is a solid-state welding process that doesn’t rely on melting the base materials. Instead, a rotating tool generates frictional heat that softens the metals, allowing them to be stirred and joined together under pressure.
FSW is particularly effective for aluminium and non-ferrous metals, and it’s often used in the transportation and aerospace sectors. This method is also advantageous for joining dissimilar materials or alloys that are difficult to weld using traditional arc processes.
The reduced heat input helps minimise distortion, and the process produces strong, defect-free joints, making it ideal for lightweight structures requiring high integrity.
3. Plasma Arc Welding
A close relative of TIG welding, plasma arc welding offers even greater control by focusing the arc through a narrow nozzle, producing a more concentrated and hotter arc. This allows for extremely precise welds, even on narrow grooves and hard-to-reach joints.
Plasma welding is particularly suited for high-precision industrial components, including heat exchangers, instrumentation tubing, and stainless steel assemblies that demand flawless results. Its ability to operate at high temperatures makes it effective for crack-resistant welds, especially in materials prone to thermal stress.
4. Electron Beam Welding
Electron beam welding (EBW) is a high-energy process that uses a focused beam of electrons to generate deep, narrow welds. It must be performed in a vacuum environment, making it less common in standard fabrication workshops, but extremely valuable for critical applications.
This technique is ideal for very thick sections or where access is limited to one side of the joint. EBW is often used in the aerospace, nuclear, and defence industries due to its ability to produce clean, precise, and ultra-strong welds with minimal distortion.
Though not frequently used in general structural steel fabrication, EBW plays a crucial role in components subject to extreme loads or fatigue.
5. Spot Welding (Resistance Welding)
Spot welding, also known as resistance welding, is a widely used method for joining overlapping sheets of metal, especially in mass production environments. It works by applying pressure and electrical current to a small area, fusing the metals at a single point.
This process is highly efficient, producing fast, repeatable welds with minimal consumables. It is commonly used in the automotive industry, appliance manufacturing, and metal furniture production, where speed and consistency are vital.
Spot welding is easily integrated into automated systems, making it a key component of modern assembly lines.
Modern Welding Techniques and Equipment
The success of industrial welding projects doesn’t rely solely on the choice of process, it also depends on the use of appropriate equipment and skilled labour. At Vulcanus Stahl, we combine modern welding automation with highly trained professionals, enabling us to deliver both precision and flexibility across a range of project types.
Automated vs Manual Welding
For large-scale or repetitive welds, such as long seams or high-volume fabrication, robotic welding systems offer superior efficiency, consistency, and speed. These systems minimise human error and are ideal for heavy-duty steel fabrication, such as pressure vessels or machine bases.
However, not all joints are straightforward. Manual welding remains essential for complex geometries, tight spaces, or custom components where expert judgment and dexterity are required.
Vulcanus Stahl leverages both robotic and manual welding approaches to deliver optimal outcomes, depending on the complexity, volume, and tolerance requirements of each project.
Non-Destructive Testing and Quality Control
To ensure the structural integrity of every welded joint, we perform non-destructive weld testing (NDT) using methods such as:
- Ultrasonic testing
- Magnetic particle inspection
- Visual inspection by certified professionals
These techniques allow us to verify weld quality without compromising the component itself. NDT plays a crucial role in upholding welding inspection standards and fulfilling project-specific requirements for safety and performance.
Combined with our internal quality management system, this ensures full welding compliance in Germany and across the EU, even in highly regulated sectors.
Applications: Where These Welding Types Are Used
Understanding where and how different welding methods are applied helps highlight their role in delivering reliable, long-lasting industrial solutions. At Vulcanus Stahl, our certified welding capabilities support a wide range of applications in the heavy manufacturing sector.
Machine and Plant Construction
Our welded components form the foundation of high-load industrial machinery and plant infrastructure. From frames and bases to support structures and pressure-resistant enclosures, we provide custom steel assemblies up to 10 tonnes in weight.
Welding in this sector must meet strict tolerance and strength requirements, especially when components are subject to dynamic forces or thermal exposure.
Our team ensures that each assembly is produced with the appropriate welding method for the base material, geometry, and operational conditions.
Structural and Load-Bearing Steel
Structural welding plays a vital role in bridges, support beams, industrial platforms, and crane structures. These components must withstand enormous stress over extended lifespans without failure.
Welding in these applications must adhere to rigorous standards for load-bearing capacity and fatigue resistance. We apply advanced methods, such as multi-pass submerged arc welding and controlled heat input techniques, to ensure the reliability of every joint.
This is particularly important when working with high-strength steels, where weld quality directly affects safety and service life.
Choosing the Right Welding Method for Your Projects
Understanding the different types of welding, from MIG and TIG to advanced techniques like laser and electron beam welding, is essential when working with high-performance steels in demanding environments. Each method offers unique advantages depending on material type, application, and structural requirements.
At Vulcanus Stahl, we bring decades of expertise in certified industrial welding, delivering custom-fabricated steel assemblies that meet the highest European standards, including EN 1090-2 EXC3 and ISO 3834-2. Whether you need precise welds for heat-resistant alloys or robust joints for heavy machinery frames, our team is equipped with the skills, technology, and quality control to deliver lasting results.
If you’re looking for a reliable partner for welded steel assemblies up to 10 tonnes, visit Vulcanus to explore our welding capabilities or request a tailored consultation.